Department of Technical Education

Diploma Course in Automobile Engineering

Third Semester
Subject: Automobile Repair and Maintenance Lab

Contact Hrs / Week : 6 Hrs Contact Hrs / Semester : 96 Hrs

Sl.No. Topic Hrs. Allotted.

1 Safety precautions 3
2 Over hauling of clutch 9
3 Over hauling of gearbox and transfer case 12
4 Over hauling of universal joint and propeller shaft 3
5 Over hauling of rear wheel and differential 9
6 Over hauling of front axle 6
7 Understand the over hauling of steering system 9
8 Over hauling independent suspension 6
9 Over hauling of leaf springs 6
10 Over hauling of brake system 9
11 Wheel alignment 3
12 Checking alignment of frame 3
13 Revision and test 6
14 Visit to Local workshops, show-rooms , Industries 12
Total Hrs. 96

General Educational Objectives:

1 Understand the safety precautions to be observed in the workshop

2 Understand the overhauling of different types of clutches and its adjustments
3 Understand overhauling of different types of gear boxes & transfer case.
4 Understand the overhauling of universal joints and propeller shaft.
5 Understand the overhauling of finial drive assembly
6 Understand the overhauling of front axle
7 Understand the overhauling of steering system
8 Understand the overhauling of front independent suspension system
9 Understand the overhauling of leaf springs
10 Understand the breaking system in the vehicle
11 Know the importance of wheel alignment
12 Know the alignment of frames
List of Exercise :

1. Overhauling of a Single plate clutch. (coil spring type)

2. Overhauling of a Single plate clutch. (Diaphragm spring type)
3. Overhauling of a multi-plate clutch.
4. Overhauling of a sliding mesh Gear-box, & calculation of gear-ratio’s w.r.t number of teeth.
5. Overhauling of a constant-mesh Gear-box & calculation of gear-ratio’s w.r.t number of teeth.
6. Overhauling of a synchro-mesh Gear-box & calculation of gear-ratio’s w.r.t number of teeth.
7. Overhauling of a Transfer case.
8. Overhauling of a Propeller shaft & universal joint
9. Overhauling of a Final drive & Differential with backlash adjustment, & calculation of Final drive gear
ratio
10 Overhauling of a front axle & hub greasing.
11 Overhauling of a Steering gear box with Backlash , End-play adjustment & calculation of steering gear
ratio. ( minimum any three different types of steering gear box)
12 Overhauling of an Independent suspension system.
13 Overhauling of a Leaf spring & re-chambering.
14 Overhauling of a Steering gear box
15 Overhauling of a mechanical brake with free-play & brake shoe adjustments .
16 Overhauling of a disc brake
17 Overhauling of a Master cylinder & wheel cylinder.
18 Bleeding of hydraulic brake system , free-play & brake shoe adjustments.
19 Measurement of Wheel base, wheel track, Toe-in, Toe-out, over length, over all height, front over-hang,
rear over-hang, ground clearance.
20 Checking the alignment of chassis frame.

Important Note :

1. Overhauling includes Dismantling, Cleaning, Inspection, Repair / Replacement of worn parts,

Reassembling with necessary adjustments.
2. For every Exercises mention the detailed Trouble shooting chart in the Lab records.
3. The lab-record must have the following contents for each exercise :

a. Aim .
b. Tools & Equipments required
c. Procedure
d. Precautions if any
e. Results / Reports
f. Troubling shooting chart.

SCHEME OF EVALUATION

Serial no Description Marks

Writing procedure

1 a) One exercise from list of exercises 1-9 (10+10) = 20

b) One exercise from list of exercises 10-20
 Conducting & Performance
2 (30+25) = 55
a) One exercise from list of exercises 1-9
b) One exercise from list of exercises 10-20

3 Viva-voice 20

4 Lab-record 05

Total 100

TOOLS & EQUIPMENT LIST REQUIRED FOR THE LAB

1. Mechanic tool kit

2. Torque wrench ( 0-200 Nm)
3. Arbar press
4. Hydraulic press (20 Tons )
5. Hydraulic trolley jack
6. Hydrullic/ Mechanical jacks
7. Dial gauges with magnetic stand, feeler gauges,
8. Air compressor
9. Electronic Tyre inflators
10. Two post hoist
11. Tripod stands
12. Three jaw bearing pullers

LIST OF COMPONENTS REQUIRED

1. Single plate clutches ( Coil & Diaphragm spring type )
2. Multi plate clutch
3. Gear boxes ( sliding, constant & synchromesh mesh )
4. Transfer case
5. Propeller shaft assembly
6. Rear axle assembly with wheels
7. Front axle assembly with wheels
8. Steering gearbox assemblies ( different types )
9. Chassis frame with Independent & leaf spring suspension system
10. Mechanical brake assemblies
11. Hydraulic brake system
12. Disc brake assemblies.